Hollow drive shaft using upsetting method and manufacturing method therefor

ABSTRACT

Provided are a hollow drive shaft using an upsetting method and a method of manufacturing the same, in which hot forging and upsetting processes are applied to both ends of a workpiece so that an outer diameter at both ends of the workpiece is greater than an outer diameter of a middle part of the workpiece, thereby reducing a weight of the drive shaft and enabling the drive shaft to transmit higher driving power. According to the present invention, the upsetting process is applied during the hot forging process to manufacture the hollow drive shaft, portions to be substantially processed are limited to portions at both ends of the workpiece, and the number of upsetting processes is limited to a minimum number (2 or the like), such that initial investment costs and manufacturing costs are low because the number of processes is small.

FIELD

The present invention relates to a method of manufacturing a hollowdrive shaft for a vehicle, and more particularly, to a hollow driveshaft using an upsetting method and a method of manufacturing the same,in which hot forging and upsetting processes are applied to both ends ofa workpiece so that an outer diameter at both ends of the workpiece isgreater than an outer diameter of a middle part of the workpiece,thereby reducing a weight of the drive shaft and enabling the driveshaft to transmit higher driving power.

BACKGROUND

In general, a drive shaft is installed in a vehicle in order to transmitpower to two left and right wheels of the vehicle from a transaxledriven by power from a transmission that performs a gear shiftingoperation on power of an engine.

Because a solid drive shaft causes an increase in weight of a vehiclebody as well as high noise, there is a disadvantage in that a separatedamper needs to be mounted on the drive shaft.

Vehicle manufacturers have consistently replaced the solid drive shaftswith hollow drive shafts in order to reduce weights of the vehicles andreduce noise.

The hollow drive shaft decreases in weight by 30 to 40% and increases inrigidity by about 30% in comparison with the solid drive shaft, suchthat it is possible to solve a problem with resonance.

Types of hollow drive shafts for a vehicle in the related art include a3-pieces welded type in which stub shafts are joined, by frictionwelding, to two left and right sides of a hollow shaft having a hollowportion at a center thereof, and a 1-piece swaged type in which one pipeworkpiece is integrally manufactured by a swaging process.

The hollow drive shaft manufactured by the friction method causes aproblem of an increase in manufacturing costs because a total of threesub-components including one pipe and two stub shafts are required tomanufacture one component, the stub shafts need to be coupled, byfriction welding, to both ends of the pipe, and then a bead cuttingprocess and an additional polishing process need to be additionallyperformed on an outer surface of the hollow drive shaft.

In addition, the friction welding cannot obtain a uniform metal flow,and it is difficult to satisfy durability required for the drive shaftdue to welded portions.

The hollow drive shaft, which is manufactured by the swaging process, isprovided to solve the above-mentioned problems, but has a problem inthat initial investment costs are high and manufacturing cost areincreased because the swaging process including maximum eight stepsneeds to be performed.

Because the swaging process is performed in a cold state, there is ahigh risk in that cracks are formed inside and outside the workpiecewhile the workpiece undergoes rapid plastic processing, and as a result,there is a problem in that a defect rate is remarkably increased ordurability is rapidly decreased.

In addition, because the swaging process is a cold forging process,there is a drawback in that noise is very severely generated, whichcauses a deterioration in working environment.

Recently, the hollow drive shaft has an increased outer diameter at bothends thereof, and thus a constant velocity joint and a ball cage, whichare fastened to both ends of the hollow drive shaft, have increaseddiameters, such that it is possible to increase the number of balls andthus to transmit higher driving power.

However, because the swaging process cannot separately increase theouter diameters at both ends of the hollow drive shaft, there is aproblem in that it is impossible to manufacture a structure of thehollow drive shaft, only the outer diameters at both ends of which maybe increased.

SUMMARY

The present invention has been made in an effort to solve theabove-mentioned problems, an object of the present invention is toprovide a hollow drive shaft using an upsetting method and a method ofmanufacturing the same, in which hot forging and upsetting processes areapplied to both ends of a workpiece so that an outer diameter at bothends of the workpiece is greater than an outer diameter of a middle partof the workpiece, thereby reducing a weight of the drive shaft andenabling the drive shaft to transmit higher driving power.

In order to achieve the above-mentioned object, a method ofmanufacturing a hollow drive shaft using an upsetting method accordingto the present invention includes: inserting both ends of a workpiececut to a predetermined length into a heating unit and heating both endsof the workpiece to a predetermined temperature; and inserting both endsof the heated workpiece into a forming die and then pressing both endsof the heated workpiece with a mandrel in order to perform an upsettingprocess so that an outer diameter at both ends of the workpiece isgreater than an outer diameter of a middle part of the workpiece, andfurther includes: performing, after completing the performing of theupsetting process, a CNC machining process of performing turningmachining on both ends of the workpiece, which has been subjected to theupsetting process, to a predetermined dimension and shape by using acomputer numerical control (CNC) lathe; performing, by using a formrolling machine, a rolling process to form splines at both ends of theworkpiece that has been subjected to the CNC machining process;performing a high-frequency heat treatment process of heating, by usinga high-frequency heat treatment device, the workpiece, which has beensubjected to the rolling process, to a predetermined temperature,cooling and quenching the workpiece, heating again, by using thehigh-frequency heat treatment device, the quenched workpiece to apredetermined temperature, and then cooling and tempering the workpiece;performing, after performing the high-frequency heat treatment process,a correction process of correcting a changed dimension by using a press;and performing a painting process of forming a paint film in order toensure an aesthetic appearance and corrosion resistance.

A hollow drive shaft for a vehicle using an upsetting method accordingto the present invention includes: a middle part which is a middleportion of the drive shaft and has a hollow portion formed therein; andboth ends of the drive shaft each having therein a hollow portion thatcommunicates with the middle part, and having, by applying an upsettingprocess, a greater outer diameter and a larger thickness than the middlepart.

A hollow drive shaft for a vehicle using an upsetting method accordingto the present invention includes: a middle part which is a middleportion of the drive shaft and has a hollow portion formed therein; andboth ends of the drive shaft each having therein a hollow portion thatcommunicates with the middle part, and having, by applying an upsettingprocess, a greater outer diameter and a larger thickness than the middlepart, and a smaller inner diameter than the middle part.

A hollow drive shaft for a vehicle using an upsetting method accordingto the present invention includes: a middle part which is a middleportion of the drive shaft and has a hollow portion formed therein; andboth ends of the drive shaft each having therein a hollow portion thatcommunicates with the middle part, and having, by applying an upsettingprocess, a smaller inner diameter than the middle part, and an equalouter diameter to the middle part.

With the above-mentioned configuration of the present invention, theupsetting process is applied during the hot forging process tomanufacture the hollow drive shaft, the portions to be substantiallyprocess are limited to portions at both ends of the workpiece, and thenumber of upsetting processes is limited to a minimum number (2 or thelike), such that initial investment costs and manufacturing costs may below because the number of processes is small.

According to the present invention, the hollow drive shaft ismanufactured by the upsetting process instead of the swaging process,such that manufacturing costs may be reduced and performance of thedrive shaft may be improved.

According to the present invention, the hollow drive shaft may have theincreased outer diameter at both ends thereof, which cannot beimplemented by the swaging process, and thus a constant velocity jointand a ball cage, which are fastened to both ends of the drive shaft, mayhave increased diameters, such that it is possible to increase thenumber of balls and thus to transmit higher driving power.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are views illustrating a method of manufacturing a hollowdrive shaft according to an exemplary embodiment of the presentinvention.

FIG. 3 is a view illustrating states in which shapes of a workpiece arechanged by an upsetting process according to the exemplary embodiment ofthe present invention.

FIG. 4 is a view illustrating a primary upsetting forming processaccording to the exemplary embodiment of the present invention.

FIG. 5 is a view illustrating a secondary upsetting forming processaccording to the exemplary embodiment of the present invention.

FIGS. 6 and 7 are views illustrating a finished structure of the hollowdrive shaft according to the exemplary embodiment of the presentinvention.

FIGS. 8A and 8B is a view illustrating an upsetting forming processaccording to another exemplary embodiment of the present invention.

FIGS. 9, 10 and 11 are views illustrating a structure of the hollowdrive shaft manufactured by the upsetting forming process according tothe present invention.

FIGS. 12A and 12B is a view illustrating an upsetting forming processaccording to still another exemplary embodiment of the presentinvention.

FIG. 13 is a view illustrating a structure of the hollow drive shaftmanufactured by the upsetting forming process according to the presentinvention.

DETAILED DESCRIPTION

Throughout the specification, unless explicitly described to thecontrary, the word “comprise/include” and variations such as“comprises/includes” or “comprising/including” will be understood toimply the inclusion of stated elements, not the exclusion of any otherelements.

According to the present invention, an upsetting process is performedduring a hot forging process, portions to be substantially processed arelimited to portions at both ends of a workpiece, and the number ofupsetting processes is limited to a minimum number (2 or the like), suchthat initial investment costs and manufacturing costs may be low becausethe number of processes is small.

The present invention provides a method of manufacturing a hollow driveshaft that may have an increased outer diameter at both ends thereofwhich cannot be implemented by a swaging process in the related art.

FIGS. 1 and 2 are views illustrating a method of manufacturing a hollowdrive shaft according to an exemplary embodiment of the presentinvention.

Upsetting processing facilities according to an exemplary embodiment ofthe present invention may be separated for each process or configured ina continuous line.

The upsetting processing facility uses a hot forging process and a pressforging forming process which process a workpiece while heating theworkpiece to a room temperature or higher in accordance with types orcharacteristics of the workpieces when the workpiece is inputted.

The method of manufacturing a hollow drive shaft according to theexemplary embodiment of the present invention includes an upsettingprocess S100 and a post-treatment process S200.

The upsetting process S100 includes a cutting process S102, a primaryheating process S104, a primary upsetting process S106, a secondaryheating process S108, a secondary upsetting process S110, and anair-cooling process S112. The upsetting process may be performed once,or the upsetting process may be performed twice, three times, fourtimes, or the like in order to obtain a desired thickness at both endsof the workpiece.

Hereinafter, the present invention will be described with reference toan exemplary embodiment in which the upsetting process is performedtwice.

FIG. 3 is a view illustrating states in which shapes of a workpiece arechanged by an upsetting process according to the exemplary embodiment ofthe present invention, FIG. 4 is a view illustrating a primary upsettingforming process according to the exemplary embodiment of the presentinvention, FIG. 5 is a view illustrating a secondary upsetting formingprocess according to the exemplary embodiment of the present invention,and FIGS. 6 and 7 are views illustrating a finished structure of thehollow drive shaft according to the exemplary embodiment of the presentinvention.

As illustrated in S300 (FIG. 3), the cutting process S102 cuts a steelpipe to a predetermined length, thereby manufacturing a workpiece to beprocessed.

A workpiece 10 is a steel pipe made of steel, having a predeterminedlength and a circular cross section, and including a middle part 11 andboth ends 12 and 13.

Next, when the workpiece is inputted to the upsetting processingfacility, predetermined portions at both ends of the workpiece 10 areheated, and the workpiece is aligned at a predetermined position so thatthe upsetting process may be performed.

As illustrated in S302 (FIG. 3), the primary heating process S104inserts predetermined portions at both ends of the aligned workpieceinto a first heating unit by using an orthogonal transfer system or arobot system. The first heating unit may use various heating methodssuch as a high-frequency heating method, an electrical resistancemethod, or a gas combustion method. In particular, the high-frequencyheating method is applied to raise a temperature to a desiredtemperature ranging from 1,100° C. to 1,300° C. within a short time.

The workpiece 10, which is primarily heated as described above, istransferred to a first upsetting unit 100, and the primary upsettingprocess is performed before a temperature of the workpiece is lowered toa predetermined temperature.

As illustrated in S304 (FIG. 3), the primary upsetting process S106 is aprocess of increasing outer diameters by pressing predetermined portionsat both ends 12 and 13 of the workpiece.

The first upsetting unit 100 includes a first insertion hole 112 intowhich the workpiece 10 having a rod shape is inserted, a first formingdie 110 having a first fixing unit (not illustrated) for fixing theworkpiece, and a first mandrel 122 of a first punching die 120.

The first forming die 110 has the first insertion hole 114 formed in acavity in a direction in which the workpiece 10 is inserted, and a firstextension hole 114 in a direction in which the first mandrel 122 isinserted.

The workpiece 10 is inserted into the first insertion hole 112 of thefirst forming die 110, and one end of the workpiece 10 is fixed. Thefirst mandrel 122 of the first punching die 120 is moved in a directionopposite to the movement direction of the workpiece 10 and inserted andpressed into the first extension hole 114.

The primary upsetting process is performed so that volumes at both ends12 and 13 of the workpiece 10 are increased corresponding to a shape ofthe first extension hole 114 as the workpiece 10 is pressed by the firstmandrel 122, such that the outer diameter is increased. Ascross-sectional areas of the predetermined portions 12 and 13 at bothends of the workpiece 10, which has been subjected to the primaryupsetting process, are increased, an overall length of the workpiece isdecreased.

As illustrated in S306 (FIG. 3), the secondary heating process S108inserts the predetermined portions 12 and 13 at both ends of theworkpiece, which has been subjected to the primary upsetting process inthe first upsetting unit 100, into a second heating unit by using anorthogonal transfer system or a robot system.

The second heating unit uses the high-frequency heating method in orderto raise a temperature to a desired temperature ranging from 1,100° C.to 1,300° C. within a short time.

The workpiece 10, which is secondarily heated as described above, istransferred to a second upsetting unit 200, and the secondary upsettingprocess is performed before a temperature of the workpiece is lowered toa predetermined temperature.

As illustrated in S308 (FIG. 3), the secondary upsetting process S110 isa process of increasing the outer diameters by pressing thepredetermined portions 12 and 13 at both ends of the workpiece.

The second upsetting unit 200 includes a second insertion hole 212 intowhich the workpiece 10 having a rod shape is inserted, a second formingdie 210 having a second fixing unit (not illustrated) for fixing theworkpiece 10, and a second mandrel 222 of a second punching die 220.

The second forming die 210 has the second insertion hole 212 formed in acavity in a direction in which the workpiece 10 is inserted, and asecond extension hole 214 in a direction in which the second mandrel 222is inserted. In this case, the second extension hole 214 of the secondforming die 210 is formed to have a greater diameter than the secondextension hole 114 of the first forming die 110.

The workpiece 10 is inserted into the second insertion hole 212 of thesecond forming die 210, and one end of the workpiece 10 is fixed. Thesecond mandrel 222 of the second punching die 220 is moved in adirection opposite to the movement direction of the workpiece 10 andinserted and pressed into the second extension hole 214.

The secondary upsetting process is performed so that volumes at bothends 12 and 13 of the workpiece 10 are increased corresponding to ashape of the second extension hole 214 as the workpiece 10 is pressed bythe second mandrel 220, such that the outer diameter is increased.

Both ends 12 and 13 of the workpiece 10, which has been subjected to thesecondary upsetting process, have greater thicknesses and outerdiameters than both ends 12 and 13 of the workpiece 10 that has beensubjected to the primary upsetting process. As cross-sectional areas atboth ends 12 and 13 of the workpiece 10, which has been subjected to thesecondary upsetting process, are increased, an overall length of theworkpiece is decreased.

As illustrated in S310 (FIG. 3), because the temperature of theworkpiece 10, which has been subjected to the secondary upsettingprocess, is too high, the air-cooling process S112 transfers theworkpiece to a conveyor type cooling table and moves the workpiece to anunloading table, thereby naturally cooling the workpiece to a roomtemperature.

The post-treatment process S200 includes a computer numerical control(CNC) machining process S202, a rolling process S204, a high-frequencyheat treatment process S206, a correction process S208, and a paintingprocess S210.

The CNC machining process S202 performs turning machining on both ends12 and 13 of the workpiece 10, which has been subjected to the upsettingprocess, to a predetermined dimension and shape by using a CNC lathe.

The rolling process S204 uses a form rolling machine to form splines atboth ends 12 and 13 of the workpiece 10 that has been subjected to theCNC machining process.

The high-frequency heat treatment process S206 is a process of hardeninga surface of the workpiece 10 to ensure durability and includesquenching and tempering.

The workpiece 10, which has been subjected to the rolling process, isheated to about 950° C. by a high-frequency heat treatment device andthen cooled (quenching). The quenched workpiece has increased hardnessbut is unstable because residual stress remains on the surface of theworkpiece. Therefore, the tempering is performed to change tissue of theworkpiece to stable tissue and to reduce residual stress.

The tempering is performed by heating the quenched workpiece to 400 to650° C. by using the high-frequency heat treatment device and thencooling the workpiece.

A dimension of the workpiece is changed after the high-frequency heattreatment process is performed. Therefore, the correction process S208is performed by using an automatic press in order to ensure straightproperties that represent straightness. The painting process S210performs electro-painting that forms a paint film by applying electriccurrent to water soluble paint in order to ensure an aestheticappearance and corrosion resistance.

The hollow drive shaft 20 according to the present invention, which ismanufactured as described above, is manufactured from a single workpieceand has a hollow portion formed therein. The upsetting process allowsthe hollow drive shaft 20 to have a structure in which an outer diameterat both ends 22 and 23 of the workpiece is greater than an outerdiameter of a middle part 21 of the workpiece (see FIGS. 6 and 7).

In other words, each of both ends 22 and 23 of the hollow drive shaft 20has a greater outer diameter and a larger thickness than the middle part21, and has an equal inner diameter to the middle part 21. The outerdiameter or the thickness of the middle part 21 is not change.

According to the present invention, the hollow drive shaft 20 ismanufactured by using the upsetting process during the hot forgingprocess.

According to the present invention, the hollow drive shaft may have theincreased outer diameter at both ends thereof, which cannot beimplemented by the swaging process, and thus a constant velocity jointand a ball cage, which are fastened to both ends of the drive shaft, mayhave increased diameters, such that it is possible to increase thenumber of balls and thus to transmit higher driving power.

The present invention provides the configuration in which the upsettingprocess is performed on one of both ends 22 and 23 of the hollow driveshaft 20 for convenience of description, as illustrated in FIGS. 4 and5. However, actually, the upsetting process is simultaneously performedon both ends 22 and 23 of the hollow drive shaft 20.

FIG. 8A to 8B is a view illustrating an upsetting forming processaccording to another exemplary embodiment of the present invention,FIGS. 9 to 11 are views illustrating a structure of the hollow driveshaft manufactured by the upsetting forming process according to thepresent invention, FIG. 12A to 12B is a view illustrating an upsettingforming process according to still another exemplary embodiment of thepresent invention, and FIG. 13 is a view illustrating a structure of thehollow drive shaft manufactured by the upsetting forming processaccording to the present invention.

As illustrated in FIG. 8A, the workpiece 10 is inserted into the firstinsertion hole 112 of the first forming die 110, and one end of theworkpiece 10 is fixed. The mandrel 122 of the first punching die 120moves in the direction opposite to the movement direction of theworkpiece 10 and presses the workpiece in the horizontal direction. Adiameter of the mandrel 122 is smaller than the inner diameter of themiddle part.

The upsetting process is performed so that the volumes at both ends 12and 13 of the workpiece 10 are increased corresponding to the shape ofthe first extension hole 114 as the workpiece is pressed by the mandrel122, such that the outer diameter is increased.

As illustrated in FIG. 8B, the first forming die 110 forms a structuresuch that when the mandrel 122 is separated in the movement direction ofthe workpiece 10, an inner diameter at each of both ends 22 and 23 ofthe workpiece is smaller than an inner diameter of the middle part 11 ofthe workpiece 10.

As illustrated in FIGS. 9 to 11, the hollow drive shaft 20 ismanufactured from a single workpiece and has a hollow portion formedtherein. The upsetting process allows the hollow drive shaft 20 to havea structure in which the outer diameter is increased and the innerdiameter is decreased at both ends 22 and 23 of the workpiece. In otherwords, each of both ends 22 and 23 of the hollow drive shaft 20 has agreater outer diameter and a larger thickness than the middle part 21,and has a smaller inner diameter than the middle part 21.

As illustrated in FIG. 12A, the workpiece 10 is inserted into the firstinsertion hole 112 of the first forming die 110, and one end of theworkpiece 10 is fixed. The mandrel 122 of the first punching die 120moves in the direction opposite to the movement direction of theworkpiece 10 and presses the workpiece in the horizontal direction.

The inside of the workpiece 10 penetrate to both ends 12 and 13 of theworkpiece 10 by being pressed by the mandrel 122.

As illustrated in FIG. 12B, the first forming die 110 forms a structurein which when the mandrel 122 is separated in the movement direction ofthe workpiece 10, an outer diameter of the middle part 11 of theworkpiece 10 is equal to an outer diameter at each of both ends 22 and23, and an inner diameter at each of both ends 22 and 23 of theworkpiece is smaller than an inner diameter of the middle part 11.

As illustrated in FIG. 13, the hollow drive shaft 20 is manufacturedfrom a single workpiece and has a hollow portion formed therein. Theupsetting process allows the hollow drive shaft 20 to have a structurein which an inner diameter is decreased at both ends 22 and 23 of theworkpiece.

In other words, each of both ends 22 and 23 of the hollow drive shaft 20has a smaller inner diameter than the middle part 21, and has an equalouter diameter to the middle part 21.

The above-mentioned exemplary embodiments of the present invention arenot implemented only by an apparatus and a method. Based on theabove-mentioned descriptions of the exemplary embodiments, those skilledin the art to which the present invention pertains may easily realizethe exemplary embodiments through programs for realizing functionscorresponding to the configuration of the exemplary embodiment of thepresent invention or recording media on which the programs are recorded.

Although the exemplary embodiments of the present invention have beendescribed in detail hereinabove, the right scope of the presentinvention is not limited thereto, and it should be clearly understoodthat many variations and modifications made by those skilled in the artusing the basic concept of the present invention, which is defined inthe following claims, will also belong to the right scope of the presentinvention.

The present invention is intended to improve performance of a driveshaft by applying an upsetting process during a hot forging process tomanufacture the hollow drive shaft, and manufacturing the hollow driveshaft by using the upsetting process instead of a swaging process whilelimiting portions to be substantially processed to portions at both endsof a workpiece.

1.-8. (canceled)
 9. A hollow drive shaft for a vehicle, comprising: amiddle part having a hollow portion therein as a middle portion of thedrive shaft; and both ends having a hollow portion therein tocommunicate with the middle portion, wherein the both ends of the hollowdrive shaft has a greater thickness than the middle portion by applyingan upsetting process including heat treatment.
 10. The hollow driveshaft of claim 9, wherein the hollow drive shaft is formed by insertinga mandrel into a through hole of a steel pipe between a forming die anda punching die by the upsetting process.
 11. The hollow drive shaft ofclaim 10, wherein the hollow drive shaft is manufactured by decreasingthe overall length as the cross-sectional area of the steel pipe isincreased by the upsetting process.
 12. The hollow drive shaft of claim9, wherein the hollow drive shaft is manufactured without cold forgingof the swaging process or sub-component coupling of friction welding.13. The hollow drive shaft of claim 9, wherein the hollow drive shaft isfor increasing a diameter of a constant velocity joint and a ball cagefastened to both ends of the hollow drive shaft and increasing thenumber of balls of the ball cage to transmit higher driving power. 14.The hollow drive shaft of claim 9, wherein the both ends are, by theupsetting method, a larger outer diameter than the middle portion, thesame outer diameter as the middle portion, the same inner diameter asthe middle portion, or a smaller inner diameter than the middle portion.